Closed-Die Rebar Upset Forging for Precise Head Diameter
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Solution Overview
Problem
Existing forging machines for deformed reinforcement bars face challenges in achieving consistent upset diameter and shape due to variations in rebar diameters and rib dimensions, leading to inadequate clamping, incomplete closing of dies, and issues with automation.
Innovation Solution
A forging machine design with separate casings for clamping and upsetting dies, where clamping dies are split and can be closed independently, and the upsetting die is a solid die with a closed radial cross-section, allowing for true closed-die forging and precise control over the upset diameter and shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If clamping dies and upsetting dies are housed in the same pair of casings, then the structure is simpler, but the clamping force is insufficient for larger diameter rebars and the upsetting cavity dimensions cannot be precisely controlled
Solution Approach 1:
The patent divides the original single casing structure into two separate casings: a first casing housing the clamping dies and a second casing housing the upsetting dies. This segmentation allows independent control of clamping force and upsetting cavity dimensions, enabling precise control of upset diameter while maintaining structural simplicity through modular design.
2Device complexity
If clamping dies and upsetting dies are housed in the same pair of casings, then the device structure is more compact, but the upsetting cavity dimensions vary with rebar diameter leading to inconsistent upset quality
Solution Approach 1:
By separating the clamping and upsetting functions into different casings, the patent enables the upsetting cavity dimensions to remain constant regardless of rebar diameter variations. The second casing houses a solid upsetting die with a fixed cavity that maintains consistent dimensions, ensuring uniform upset quality across different rebar sizes while keeping the overall device compact through coordinated casing design.
3Device complexity
If clamping dies and upsetting dies are housed in the same pair of casings, then the opening and closing mechanism is simpler, but automation is difficult due to rebar sticking after upsetting
Solution Approach 1:
The patent separates the clamping and upsetting operations into independent casing systems, allowing the first casing to open and close the clamping dies independently after upsetting is complete. This independent control prevents rebar sticking by releasing clamping force while maintaining upset shape, enabling automated operation without manual intervention to remove stuck rebars.
4Device complexity
If clamping dies and upsetting dies are housed in the same pair of casings, then the overall device size is smaller, but the radial expansion force during upsetting requires excessive clamping force
Solution Approach 1:
By housing the upsetting dies in a separate second casing, the patent isolates the radial expansion force generated during upsetting from the clamping force requirement. The first casing can apply moderate clamping force without needing to counteract large radial expansion forces, as these are independently managed by the second casing housing the solid upsetting die, reducing overall force requirements while maintaining compact device size.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design ensures accurate and uniform upset dimensions, prevents rebar sticking, and facilitates automated operation by maintaining a consistently closed cavity, improving roundness and reducing wear on thread cutting tools.
Implementation Method 1
the heading tool (4) moves forward and upsets the rebar (100) in the upsetting cavity (30), so that the rebar (100) expands radially and the upset head (110) is formed
Implementation Method 2
The clamping dies (1, 2) secure the rebar (100) in the clamping cavity (10) against the forging force
Data Source
AI summary
A machine and its associated process for upset forging the ends of deformed reinforcement bars are disclosed. The machine includes 2 split clamping dies and an upsetting die, and they are housed in separate casings so that the clamping action is independent from the upsetting die. The clamping dies and the upsetting die form a continuous cavity for accommodating the forging of long bars. The upsetting die has a upsetting cavity with radial closed cross-section, and the whole forging process is performed inside this closed cavity to ensure it's a true closed-die forging process, which results in precise upset diameter with improved roundness of the rebar.